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7 Foreword, Small survey (1/2) – about french lessons… (1/2) Lessons about industrialization UTC –> more focused on quality Produit-process Télécom Industrialization engineer is in charge of definition and optimization of the product manufacturing plan so as achieving cost, cycle time, quantity and quality objectives. Academic Point of view

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9 Foreword A multi competences man ! Being able to dialog with several partners: Control risks, @ the interface of production, process, planification, supply chain, quality marketing (for demand analysis). Required to know how to manage a project, design an organization and drive it Personal behavior : manage the complexity, be the interface man ! Ressources

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15 What is industrialization ? Some numbers in service organisation: –A law is adopted : each person can benefit of the RMI (french accronym for Minimal Social Income) Grow up from 0 to 17000 peoples in a dep. 79 ~ peoples to help per working day (217d/y in France) WOQIEWOQIE

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16 What is industrialization ? Some numbers in cinematography industry: –1 Best seller film: ~15M -part vite reviens tard 3MP see it in 3 Months Mean projection room size : 300seats 3334 rooms associated to this film to achieve this goal and produce : CA = ~21M η = 40% of benefits in 3 months How to pass from 0 to 3334 rooms, attract and manage 3MP ? WOQIEWOQIE

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17 What is industrialization ? Some numbers in semiconductor industries: –A new technology each 2 years. –1 technology cost ~ 1b$ –1 technology involve ~500 engineers in project mode –Production window: from only 2y up to 5 years. –Yield of the first silicon: less than 50% –Reach a stable prod @ a scrap rate : 2% + yield @ 75% –Decrease wafer from 10k$ to 0,5k$ WOQIEWOQIE

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32 What is industrialization ? Management principle: –Achieve targets, changing mentality and behavior at least toward the product by ramping the production up. –A systematic approach declined for each indicator: Cycle time: attacking each pocket of wasted time during the production. Quality: their is no more place for raw quality, non quality Cost: each island of spending has to be reduce Environment: No ecological fingerprint is allowable Ethic: Each behavior must be in line with organization ethical principle. WOQIEWOQIE

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38 Organization & industrialization WOQIEWOQIE Leader recognized person in the orga (charismatic?), transversal function Groupe member; able to follow methods, like to work in group, positive action in the group Launch MaturationProductionStop Technology n life cycle Member profile

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48 Audit Conclusions: 5 procedures of risks managment held by 5 different organizations Integration, quality, production, engineering, maintenance 5 structrures based on the same model: Collect/Record the risk, Manage the risk investigate, synthesis All these procedures are isolated from each others insterad of being linked ! WOQIEWOQIE Organization & industrialization

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50 Organization and Industrialization Facts Underline an other reality for the « Wafer aligner » element 3 occurrences over 13 weeks 12 per year: If FMEA have been updated RPN ranking grow up from 10 to 25 OCC will pass from 2 to 5 WOQIEWOQIE

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69 What we know To have a control by expertise poles To structure and monitor the life cycle of a technology To control the technology transfer with the organization To be Reactive Improvement ways To have a big picture of interactions Support: –interactions –Process control evolutions –Transfert master from a technology to another Be Proactive WOQIEWOQIE Quality & industrialization

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76 Main issue for linking risks and manufacturing ctrl plan Analysis is not performed Link does not exist between product FMEA and product control plan Customers get quality parameters and poduct risks analysis and can challenge on that point Are our control plan coherent toward customers needs ? WOQIEWOQIE Quality & industrialization

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80 Sampling plan –Sampling size by lot (number of lot between 2 measures) –Sampling size within a lot (number of product measures in a lot) –Sampling size for a measurement on a product (number of measures on a product) WOQIEWOQIE Quality & industrialization

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81 Non conform production & customer claim control –At least set an organization: to record to analyze to perform action plan –Sometimes add also the Action control ?? PDCA ?? Improvement way ? WOQIEWOQIE Quality & industrialization

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93 Automatic management of operation recipes WOQIEWOQIE Information system & industrialization Without Recipe management Automatic recipe loading, based on a local setting and storage 1) recipe for validation 2) Local modification without control 3) Loading of an uncontrolled recipe

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94 Automatic management of operation recipes WOQIEWOQIE Information system & industrialization 300Works BrookAutomati on WorkStream… Automatic recipe loading, based on a remote setting and storage 1) recipe for validation 2) Local modification without control 3) Loading of an remote controlled recipe 4) Local mode for tests only !!!!

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98 Main milestones: –Supplier choice in an international context –Financial investment: THE DO decision –Project financial control –Project review Main issues for you: –Coordinates contractors –Perform contract WOQIEWOQIE The engineering project

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99 Definitions: –Basic Engineering for a plant project is the information set about process and project planning so that an senior prime contractor can detail and drive the project until the first run of the production unit. WOQIEWOQIE The engineering project

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116 Industrialization : From work preparation and a two stage learning program A facility installation program –Preparation of work –Off line learning (R&D, Engineering training…) A learning environment to create –On line learning (Operational Goals risks prevention & mitigation) Multi point of view issues SUMMARYSUMMARY Thank you for the audience

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119 Learning Curves When new productions are set up: –Bad first lots –Production time decrease with time (sooner or later) through a learning process –Learning curves captures this wishdom in roughly following equation: WOQIELWOQIEL ti = time to produce the nth lot N: number of cumulated product Alpha: process specific parameter

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124 Learning Curves Stakes in an international competition: –Need to learn faster than competitors –Stakholders go to the more profitable in a short term period ! –Customers preferences goes to the cheaper, faster and best in quality ! Eg. NXP stakholders strategy… compete with TSMC & CR2 Alliance => TSMC is best in class => joint venture with it. WOQIELWOQIEL